Multi-beam pattern generators employing yaw correction when writing upon large substrates, and associated methods

ABSTRACT

Multi-beam pattern generators employing yaw correction when writing upon large substrates, and associated methods are disclosed. A multi-beam pattern generator may include a spatial light modulator (SLM) with independently controllable mirrors to reflect light onto a substrate to write a pattern. The pattern may be written in writing cycles where the substrate is moved to writing cycle zone locations. The light is reflected by the SLM onto the substrate by mirrors of the SLM in active positions to write the pattern upon the substrate. By determining a location and yaw of the substrate with respect to the SLM in each writing cycle, some mirrors of the SLM may be digitally controlled to either inactive positions or the active positions to compensate for the yaw of the substrate. In this manner, the pattern written upon the substrate may be precisely written with compensation for yaw.

BACKGROUND

1. Field

Embodiments of the present disclosure generally relate to apparatusesand methods for lithographic patterning and more particularly forlithographic patterning for large substrates subjected to yaw andpositioning errors.

2. Description of the Related Art

Large area substrates are often utilized in the manufacture of liquidcrystal displays (LCDs). LCDs or flat panels are commonly used foractive matrix displays such as computers, touch panel devices, personaldigital assistances (PDAs), cell phones, television monitors, and thelike. Generally, flat panels may comprise a layer of liquid crystalmaterial forming pixels sandwiched between two plates. When power fromthe power supply is applied across the liquid crystal material, anamount of light passing through the liquid crystal material may becontrolled at pixel locations enabling images to be generated.

Microlithography techniques are generally employed to create electricalfeatures incorporated as part of the liquid crystal material layerforming the pixels. According to this technique, a light-sensitivephotoresist is typically applied to at least one surface of thesubstrate. Then, either a photolithography mask or pattern generatorexposes selected areas of the light-sensitive photoresist as part of apattern with light to cause chemical changes to the photoresist in theselective areas to prepare these selective areas for subsequent materialremoval and/or material addition processes to create the electricalfeatures. The precise placement of the electrical features upon thesubstrate as part of the flat panel helps determine the quality ofresultant image generated by the flat panel as a uniform distribution ofthe pixels formed by the electrical interconnections is desirable tocorrectly reproduce the images viewed by users.

As the sizes of substrates continues to grow in the flat panel displayindustry with every subsequent generation, precise placements ofpatterns across larger distances of the substrates usingphotolithography masks has become increasingly more challenging as boththe lithography masks and substrates undergo distortions duringoperations resulting in pattern placement errors. Also, for largesubstrates, small changes in yaw may cause substantial positional errorson edges of a flat panel. Also for large substrates, a mechanicalprecision of conventional X-Y stages which support large substrates maynot be sufficient to control the patterning placement error. Therefore,new apparatuses and approaches are needed to precisely and costeffectively create patterns on large substrates.

SUMMARY

Embodiments disclosed herein include multi-beam pattern generatorsemploying yaw correction when writing upon large substrates, andassociated methods. A multi-beam pattern generator may include a spatiallight modulator (SLM) with independently controllable mirrors to reflectlight onto a substrate to write a pattern. The pattern may be written inwriting cycles where the substrate is moved to writing cycle zonelocations. The light is reflected by the SLM onto the substrate bymirrors of the SLM in active positions to write the pattern upon thesubstrate. By determining a location and yaw of the substrate withrespect to the SLM in each writing cycle, some mirrors of the SLM may bedigitally controlled to either inactive positions or the activepositions to compensate for the yaw of the substrate. In this manner,the pattern written upon the substrate may be precisely written withcompensation for yaw.

In one embodiment a pattern generator is disclosed. The patterngenerator may include a stage configured to support a substrate and movethe substrate to different writing cycle zone positions with respect toa SLM for each of a plurality of writing cycles. The pattern generatormay also include a light source configured to emit light. The patterngenerator may also include the SLM. Each mirror of the SLM beingconfigured to be individually digitally controlled from an inactiveposition to an active position during the writing cycles to reflect arespective portion of the light to the substrate. The pattern generatormay also include a computer processor configured to receive pattern datacomprising an arrangement of polygons of the pattern and to identifywhether the mirrors of the SLM are to be actuated to active positionsduring each of the writing cycles. The computer processor is configuredto compensate for yaw of the substrate in each of the writing cycles bydigitally controlling respective mirrors of the SLM to active orinactive positions. In this manner, precise placement of the patternupon the substrate may be accomplished with reduced pattern placementerrors related to yaw.

In another embodiment, a method of writing a pattern with a multibeampattern generator is disclosed. The method may include writing portionsof the pattern within a writing cycle zone location during writingcycles upon a substrate with optical beams of light by determining anddigitally controlling respective ones of mirrors of a SLM to either anactive position or an inactive position. The method may also includemoving the substrate with respect to the SLM to another writing cyclezone location for each of the writing cycles. The method may alsoinclude determining yaw of the substrate for each of the writing cycles.The digitally controlling respective ones of mirrors includescompensating for the determined yaw by controlling the mirrors to eitherthe activate or inactive positions. In this manner, the placement errorof the pattern upon large substrates may be minimized.

Additional features and advantages will be set forth in the detaileddescription which follows, and in part will be readily apparent to thoseskilled in the art from that description or recognized by practicing theembodiments as described herein, including the detailed description thatfollows, the claims, as well as the appended drawings.

It is to be understood that both the foregoing general description andthe following detailed description present embodiments, and are intendedto provide an overview or framework for understanding the nature andcharacter of the disclosure. The accompanying drawings are included toprovide a further understanding, and are incorporated into andconstitute a part of this specification. The drawings illustrate variousembodiments, and together with the description serve to explain theprinciples and operation of the concepts disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features of embodiments ofthe present invention can be understood in detail, a more particulardescription of embodiments of the invention, briefly summarized above,may be had by reference to embodiments, some of which are illustrated inthe appended drawings. It is to be noted, however, that the appendeddrawings illustrate only typical embodiments of this invention and aretherefore not to be considered limiting of its scope, for embodiments ofthe invention may admit to other equally effective embodiments.

FIG. 1A is a schematic top view of a portion of a spatial lightmodulator (SLM) of an exemplary multi-beam pattern generator writing acorner of a polygon upon a substrate in a first writing cycle whereinactuated mirrors of the SLM writing the corner are identified;

FIG. 1B is a schematic top view of another portion of the spatial lightmodulator (SLM) in FIG. 1A writing the corner of the polygon upon thesubstrate in a subsequent writing cycle wherein the substrate is subjectto yaw;

FIG. 1C is a top perspective schematic view of the multi-beam patterngenerator of FIGS. 1A and 1B illustrating an exemplary configuration oflaser interferometers determining positional changes of a stagesupporting the substrate exhibiting the yaw of FIG. 1B;

FIG. 1D is a top perspective view of an exemplary embodiment of themulti-beam pattern generator of FIG. 1C;

FIG. 2 is a top schematic view of the SLM of FIGS. 1A-1C illustratingactive positions and inactive positions of the mirrors of the SLM;

FIG. 3 is a partial top schematic view of the configuration of laserinterferometers of FIGS. 1A-1C measuring positional changes in the stagesupporting the substrate with the configuration of laser interferometersmeasuring position changes of corners on opposite sides of a diagonal ofthe rectangular-shaped substrate;

FIG. 4 is a flow chart diagram of an exemplary process of writing apattern upon a substrate with the multi-beam pattern generator of FIGS.1A-1C;

FIG. 5 is partial top schematic view of another embodiment of aconfiguration of laser interferometers compatible with the multi-beampattern generator of FIGS. 1A-1C with at least two laser interferometersat each of the four sides of the stage having a rectangular shapemeasuring positional changes, including yaw, of the stage; and

FIG. 6 is partial top schematic view of another embodiment of aconfiguration of laser interferometers directly measuring positionalchanges of the substrate, including yaw, and compatible with the patterngenerator of FIGS. 1A-1C.

To facilitate understanding, identical reference numerals have beenused, where possible, to designate identical elements that are common tothe figures. It is contemplated that elements and features of oneembodiment may be beneficially incorporated in other embodiments withoutfurther recitation.

DETAILED DESCRIPTION

Reference will now be made in detail to the embodiments, examples ofwhich are illustrated in the accompanying drawings, in which some, butnot all embodiments are shown. Indeed, the concepts may be embodied inmany different forms and should not be construed as limiting herein;rather, these embodiments are provided so that this disclosure willsatisfy applicable legal requirements. Whenever possible, like referencenumbers will be used to refer to like components or parts.

Embodiments disclosed herein include multi-beam pattern generatorsemploying yaw correction when writing upon large substrates, andassociated methods. A multi-beam pattern generator may include a SLMwith independently controllable mirrors to reflect light onto asubstrate to write a pattern. The pattern may be written in writingcycles where the substrate is moved to writing cycle zone locations. Thelight is reflected by the SLM onto the substrate by mirrors of the SLMin active positions to write the pattern upon the substrate. Bydetermining a location and yaw of the substrate with respect to the SLMin each writing cycle, some mirrors of the SLM may be digitallycontrolled to either inactive positions or the active positions tocompensate for the yaw of the substrate. In this manner, the patternwritten upon the substrate may be precisely written with compensationfor yaw.

As an introductory background before discussing features in detail,FIGS. 1A through 1C are schematic views of an exemplary patterngenerator 14 writing a pattern 15 upon a substrate 16. The substrate 16may comprise, for example, a display panel, touch panel, or continuousroll of feedstock moving through a roll-to-roll system. The pattern 15may be written in a plurality of writing cycles WC of the patterngenerator 14 which may occur at speeds of at least five (5) kilohertz.In each writing cycle WC, one or more of a plurality of optical beams18(1)-18(N) may propagate parallel or substantially parallel along aplurality of optical pathways 24(1)-24(N) leading from a SLM 12 of thepattern generator 14 to create a respective writing cycle zone locationWCZL upon the substrate 16. The SLM 12 may have at least a quantity of“N” mirrors associated with respective ones of the optical beams18(1)-18(N). Each of the writing cycles WC may include a rest time inwhich the optical beams 18(1)-18(N) are not incident upon the substrate16, and a dwell time when one or more of the optical beams 18(1)-18(N)may propagate through a respective one or more of the optical pathways24(1)-24(N) to the writing cycle zone location WCZL. The substrate 16may be moved a velocity V_(XY) relative to the SLM 12, creating aplurality of writing cycle zone locations WCZL in which each of theoptical beams 18(1)-18(N) may contribute photonic energy to thesubstrate 16 for each of the writing cycles WC. The writing cycle zonelocations WCZL1, WCZL2, . . . may partially overlap and the pattern 15may be written as the integral sum of the photonic energy transferred bythe optical beams 18(1)-18(N) to the substrate 16 during the writingcycles WC. By determining the yaw of the substrate 16 during eachwriting cycle WC using a configuration of laser interferometers asdiscussed later, the optical beams 18(1)-18(N) reflected from the SLM 12may be turned on or off the substrate 16 in each of the writing cyclesWC to compensate for the yaw. In this way, pattern placement accuracymay be improved upon the substrate 16.

It is noted that in some embodiments of the pattern generator 14, thesubstrate 16 may be moved at the velocity V_(xy) before, during, andafter the writing cycles WC. As the substrate 16 may be moved todetermined X,Y positions associated with associated ones of the writingcycle zone locations WCZL, the optical beams 18(1)-18(N) may write (or“flash”) the portion of the pattern 15 associated with the WCZL onto thesubstrate 16. The yaw of the substrate 16 may be determined as atrailing point average from many metrology measurements of the substrate16, so the clock frequency of metrology measurements of the substrate 16may be many times the frequency of the writing cycle WC. In this manner,the yaw may be determined and utilized as the substrate 16 maycontinuously move to provide efficient writing.

With this introduction, FIG. 1A is a schematic top view of a portion 10Aof the SLM 12 of the multi-beam pattern generator 14 writing a corner 35of a polygon 19 as part of the pattern 15. The polygon 19 may be withina writing cycle zone location WCZL1 upon a substrate 16 in an exemplarywriting cycle WC1. At least one light source 26A, 26B may be configuredto emit light 34 towards the mirrors 28(1)-28(N) of the SLM 12. Themirrors 28(1)-28(N) may be individually controlled to either reflect thelight 34 as respective ones of the optical beams 18(1)-18(N) topropagate along the optical pathways 24(1)-24(N) to the substrate 16.Alternatively, the mirrors 28(1)-28(N) may be individually controlled toreflect the light 34 away from the substrate 16.

FIG. 1B is a schematic top view of another portion 10B of the SLM 12writing the corner 35 of the polygon 19 within a subsequent writingcycle zone location WCZL2 upon the substrate 16 in an exemplary writingcycle WC2. As depicted in FIG. 1B, a yaw, which is a turning of thesubstrate 16 about a pivot point, has occurred between the writing cycleWC1 and the start of the writing cycle WC2. This yaw may be representedby a change of an angle theta1 (Δθ₁) of a vector A1 to the corner 35from a pivot point P1 which moves at velocity V_(XY). If the substrate16 were merely translated with a velocity V_(xy), in the X-directionand/or y-direction, there would be no yaw, but since the yaw hasoccurred, yaw compensation may be provided to ensure accurate patternplacement upon the substrate 16. The yaw compensation is depicted inFIG. 1B as the on-compensation pixels 25A and the off-compensationpixels 25B which result in the jagged lines 36A, 36B, respectively,converging at the corner 35 of the pattern 15. In contrast, FIG. 1A doesnot include the yaw with the vector A1 and so straight lines 27A, 27Bappear in FIG. 1A converging at the corner 35.

With reference to FIG. 1C, components of the pattern generator 14 andthe pattern 15 written by the pattern generator 14 will now bediscussed. The pattern 15 may comprise the at least one polygon 19 whichmay be related to circuitry of a flat panel display. The substrate 16may include a surface 20 with a photoresist 22 applied which may besensitive to the optical beams 18(1)-18(N). Each of the optical beams18(1)-18(N) may serve as a writing pixel that when incident upon thesubstrate 16 may cause the photoresist 22 of the substrate 16 tochemically change the photoresist 22 locally at the incidence location.In this regard, this incidence location may be chemically differentcompared to other locations of the photoresist 22 receiving differentincident photonic energy from the optical beams 18(1)-18(N). Thecumulative exposure of the optical beams 18(1)-18(N) upon thephotoresist 22 after all writing cycles may complete the writing of thepattern 15. Conventional microlithography techniques, also known as“processing,” can then be used to further develop the pattern 15 fromchemical changes to the photoresist 22 from being written by the patterngenerator 14. In an alternative to microlithography “processing,”“developing” may be used to further create the pattern 15 using chemicalmeans, for example, such as a photographic film process.

Precisely controlling the optical beams 18(1)-18(N) to locations uponthe photoresist 22 of the substrate 16 enables the pattern 15 to becreated upon the substrate 16 with pattern placement accuracy. In thisregard, the pattern generator 14 may move the substrate 16 with respectto the SLM 12 at a velocity V_(XY) to bring areas of the photoresist 22to be written within the optical pathways 24(1)-24(N) of the SLM 12traveled by the optical beams 18(1)-18(N) when exposing the photoresist22. The optical beams 18(1)-18(N) may be reflected on and off to thesubstrate 16 at the writing cycle zone location WCZL to form the pattern15 in the photoresist 22 as the substrate 16 may be moved relative tothe SLM 12 as depicted in FIG. 1C.

Specifically as depicted in FIGS. 1C and 2, to reflect the optical beams18(1)-18(N) on and off the substrate 16, the least one light source 26A,26B may illuminate mirrors 28(1)-28(N) of the SLM 12 with the light 34.Each of the mirrors 28(1)-28(N) has an active position 30A and aninactive position 30B. When various ones of the mirrors 28(1)-28(N) aresignaled by a computer processor 32 of the pattern generator 14 to be inthe active position 30A, the light 34 from the light sources 26A, 26Bmay be reflected to the substrate 16 along the optical pathways24(1)-24(N) associated with the various ones of the mirrors 28(1)-28(N)to turn “on” these optical pathways 24(1)-24(N). When various other onesof the mirrors 28(1)-28(N) are signaled by the computer processor 32 tobe in the inactive position 30B, the light 34A, 34B from the lightsource 26A, 26B may be reflected away from the substrate 16 by thesevarious other ones of the mirrors 28(1)-28(N) and thereby the localareas of the photoresist 22 at the optical pathways 24(1)-24(N) turnedoff would not be exposed.

With reference back to FIG. 1A, the SLM 12 may be operated in sequentialwriting cycles wherein the various ones of the mirrors 28(1)-28(N) maybe actuated to the active position 30A (FIG. 2) for a specified timeperiod (or dwell period) during the writing cycle WC before returning tothe inactive position 30B (FIG. 2) for the remainder of the writingcycle WC. During each of the writing cycles WC, a corresponding writingcycle zone location WCZL representing a portion of the pattern 15associated with one of the writing cycles WC may be written (or“flashed”) by the optical beams 18(1)-18(N). The writing cycle WC may beat least five (5) kilohertz. The substrate 16 may be moved at thevelocity V_(XY) before, during, and after the writing cycles WC. At thebeginning of each writing cycle WC the computer processor 32 maydetermine the precise desired location of the at least one polygon 19 ofthe pattern 15 upon the substrate 16 and any of the optical pathways24(1)-24(N) that my fall within the at least one polygon 19. If any ofthe optical pathways 24(1)-24(N) fall within the at least one polygon ofthe pattern 15, then the associated ones of the mirrors 28(P1)-28(Q1)may be actuated to the active position 30A to reflect the respectiveones of the optical beams 18(P1)-18(Q1) into these ones of the opticalpathways 24(P1)-24(Q1) to expose the at least one polygon 19 of thepattern 15. The desired locations of each of the polygons 19 may bedetermined by taking into account the yaw of the substrate 16 asdiscussed below. In this manner, the pattern 15 may be written withimproved pattern placement accuracy.

With reference back to FIG. 1B, when the substrate 16 is moved relativeto the SLM 12 to begin a subsequent write cycle, the computer processor32 may determine that a yaw has occurred. The yaw may relocate a corner35 of the polygon 19 from a position expected merely given the velocityVxy of the substrate 16 supported by the stage 40. The computerprocessor 32 may update the position of polygon 19 of the pattern 15relative to the SLM 12 and turns on respective optical pathways24(P2)-24(Q2) corresponding to the yaw of the polygon 19. The adjustmentfor yaw is represented by the jagged lines 36A, 36B in FIG. 1Bconverging to form the corner 35 of the polygon 19. The adjustment foryaw can be done “on the fly” for each writing cycle by the computerprocessor 32 as the position of the pattern 15 upon the substrate 16 maybe determined relative to the optical pathways 24(1)-24(N) of themirrors 28(1)-28(N) of the SLM 12.

FIG. 1C is a top perspective view of the multi-beam pattern generator 14comprising the SLM 12, the light sources 26A, 26B, an alignment camera38, a stage 40, optics 42, yaw detection apparatus 44, and the computerprocessor 32. Details of each of these components of the multi-beampattern generator 14 are now discussed in sequence.

The SLM 12 as introduced briefly above comprises the mirrors 24(1)-24(N)which are individually controlled by signals from the computer processor32. The SLM 12 may be, for example, a DLP9500-type digital mirror devicemade by Texas Instruments Incorporated of Dallas, Tex. The SLM 12 mayhave the plurality of mirrors 28(1)-28(N), for example, arranged in 1920columns and 1080 rows. Each of the mirrors 28(1)-28(N) of the SLM 12 maybe configured to be individually actuate-able (or digitally controlled)from an inactive position 30B to an active position 30A to reflect arespective portion of the light 34 to the substrate 16. Each of themirrors 28(1)-28(N) may reflect a portion of the light 34 to thesubstrate 16 while in the active position 30A and less than one (1)percent of this amount to the substrate 16 when in the inactiveposition. The photonic energy of the light 34 may be deposited acrossthe pattern 15 and may at least overlap between writing cycle positionsWCZL1, WCZL2. In this manner, features of the pattern 15 may bedetermined from multiple writing cycles to reduce positional error asthe energy delivered in any single writing cycle to the substrate 16 isaveraged with photonic energy delivered in other writing cycles.

Next, the alignment camera 38 may include an optical sensor, for examplea charge coupling device, to read at least one alignment mark 46 on thesubstrate 16 to register the substrate 16 to the stage 40 and the SLM12. The alignment camera 38 may be coupled to the computer processor 32to facilitate the determination of the relative locations of thepolygons of the pattern 15 upon the substrate 16. In this regard, oncethe substrate 16 may be registered via the alignment camera 38, thewriting cycles may begin.

The stage 40 may support the substrate 16 and to move the substrate 16relative to the SLM 12. The stage 40 may include at least one surface 31to support the substrate 16 in the z-direction. The stage 40 may move inaccordance to at least one motor 33 with the velocity V_(XY) in theX-direction and/or the y-direction to move the substrate 16 relative tothe SLM 12, so that the pattern 15 may fall within the optical pathways24(1)-24(N) of the mirrors 28(1)-28(N) during the writing cycles. Thestage 40 may also include at least one linear encoder (not shown) toprovide positional information to the computer processor 32 regardingchanges in the position of the stage 40 in the x-direction and/ory-direction.

Next, with continued reference to FIG. 1C, the optics 42 may include areduction ratio to reduce the size of the optical beams 18(1)-18(N) uponthe substrate 16. The reduction ratio may be in a range from 2:1 to10:1. In this regard, the optics 44 may include at least one lensincluding at least one convex surface and/or concave surface between thesubstrate 16 and the SLM 12. The optics 44 may comprise a material ofhigh transmissibility (for example: quartz) for various wavelengths ofthe light 34 to focus the optical beams 18(1)-18(N) upon the substrate16. In one embodiment, when the mirrors 28(1)-28(N) are in the activeposition 30A, the effective pitch separating optical centers of adjacentoptical beams 18(1)-18(N) from each other may be twenty-five (25)microns or less. Also, the mirrors 28(1)-28(N) may reflect the opticalbeams 18(1)-18(N) along the parallel or substantially parallel paths ofthe optical pathways 24(1)-24(N) toward the substrate 16. As the opticalbeams 18(1)-18(N) pass through the optics 44 towards the substrate 16,the effective pitch may be five (5) microns or less at the substrate 16for a reduction ratio of 5:1 for the optics 44. In this manner, a higherresolution image may be created with more precise control upon thesubstrate 16 than without the optics 42.

FIG. 1D is a top perspective view of an exemplary embodiment of themulti-beam pattern generator of FIG. 1C showing the writing mechanism 17shown in FIG. 1C mounted relative to the stage 40. The writing mechanism17 may include the optics 42, the light source 26A, 26B, the alignmentcamera 38, the computer processor 32, and the SLM 12. In this manner,the substrate 16 supported by the stage 40 may move relative to thewriting mechanism 17 to write the pattern upon the substrate 16.

Next, FIG. 3 depicts a partial top schematic view of a yaw detectionapparatus 44(1) comprising laser interferometers 48A-48D directlymeasuring a position and yaw of the stage 40 at the beginning of awriting cycle, wherein a previous position 70 of the stage 40 and aprevious position 72 of the substrate 16 in the previous writing cycleare shown in broken lines. The stage 40 may be supporting the substrate16 and may be considered to be stationary with respect to each other.The laser interferometers 48A-48D may be mounted in stationary locationsand may reflect laser beams 74A-74D, respectively, against the stage 40to directly measure a position of the stage 40, including yaw. In thisregard, the interferometers 48A-48B may reflect against adjacent sides76A, 76B of the stage 40 at a corner 78A of the stage 40 andinterferometers 48C-48D may reflect at adjacent sides 76C, 76D of thestage 40 at a corner 78B of the stage 40. The corners 78A, 78B of thestage 40 may be opposite each other across a diagonal of the rectangularshape of the stage 40. Variances of calculations of the position and/orthe yaw of the substrate 16 using different combinations of theinterferometers 56A-56D may be resolved by the computer processor 32,for example, by averaging. In this manner, the position and the yaw ofthe substrate 16 may be determined for each writing cycle.

With reference back to FIG. 1C, the computer processor 32 may in oneembodiment comprise a semiconductor device, memory, and a storagedevice. The computer processor 32 may receive the pattern data whichdefines the pattern 15 comprising the plurality of polygons 19. Theformat of the pattern data may be, for example, in a format such asGDSII or MEBES Mode 5 format. The computer processor 32 may receive thepattern data and determine the locations of the polygons 19 of thepattern data upon the substrate 16, and also the optical pathways24(1)-24(N) available for the optical beams 18(1)-18(N) to propagatealong to the substrate 16 when the respective mirrors 28(1)-28(N) of theSLM 12 are actuated to the active positions 30A. Once the computerprocessor 32 has determined the locations of the polygons 19 and theoptical pathways 24(1)-24(N) of the optical beams 18(1)-18(N) upon thesubstrate 16, then the computer processor 32 may then determine which ofthe mirrors of the SLM 12 to actuate to the active position 30A (FIG. 2)to write the pattern 15 for the writing cycle based on a writingstrategy rule which may be adjustable to the user of the patterngenerator 14.

Various embodiments of the writing strategy rule may be used by computerprocessor 32 to determine whether mirrors of the SLM 12 may be activatedto write upon the substrate 16 during a writing cycle. In oneembodiment, the writing strategy rule may comprise actuating respectiveones of the mirrors 28(1)-28(N) of the SLM 12 to the active position 30Awhen the respective ones of the optical pathways 24(1)-24(N) arepositioned over a polygon 19 of the pattern 15 intended to be written bythe optical beams 18(1)-18(N). In this manner, whether the mirrors28(1)-28(N) of the SLM 12 are actuated to the active position 30A (FIG.2) to write upon the substrate 16 during a writing cycle may bedetermined.

Now that the components of embodiments of the pattern generator 14 havebeen discussed, FIG. 4 depicts a flowchart diagram of an exemplaryprocess 100 for writing the pattern 15 with the pattern generator 14 andactuating the optical beams 18(1)-18(N) on and off to compensate for theyaw of the substrate 16. The process 100 depicted in FIG. 4 will bedescribed using the terminology and information provided above.

The process 100 may include writing portions of the pattern 15 withinthe writing cycle zone location WCZL during the writing cycles WC uponthe substrate 16 with the optical beams 18(1)-18(N) of the light 34 bydetermining and digitally controlling respective ones of the mirrors28(1)-28(N) of the SLM 12 to either the active position 30A or theinactive position 30B (operation 102A in FIG. 4). The process 100 mayalso include moving the substrate 16 with respect to the SLM 12 for eachof the writing cycles (operation 102B in FIG. 4). The process 100 mayalso include measuring yaw of the substrate 16 for each of the writingcycles (operation 102C in FIG. 4). The digitally controlling selectedones of the mirrors 28(1)-28(N) includes compensating for the measuredyaw of the substrate 16 each writing cycle. The yaw may be determinedseveral times per writing cycle WC to provide a population of yaw errordata for the computer processor 32 to average and discern high frequencyyaw errors and stage position vibration errors from low frequency stageposition vibrations. The low frequency stage position vibrations, forexample, those below a threshold frequency in a range from a half (0.5)hertz to two-hundred (200) hertz, may be sent to the motor 33 (FIG. 1C)of the stage 40 for correction. In contrast, the high frequency yawerrors and stage position vibration errors above the threshold frequencymay be assigned to the SLM 12 for correction by digitally controllingrespective mirrors 28(1)-28(N) of the SLM 12.

The process 100 may also include determining whether the pattern 15 isfully written (operation 102D in FIG. 4). If the pattern 15 is not fullywritten then the writing may continue. Otherwise, if the pattern 15 isfully written, then the process 100 may include removing the substrate16 from the pattern generator 14 (operation 102E in FIG. 4). In thismanner, the pattern 15 may be written with improved pattern placementaccuracy.

The components of the pattern generator 14 have been discussed as wellas the method 100 for writing the pattern 15 with the pattern generator14. Now other embodiments of a yaw detection apparatus 44(2)-44(3) arepossible utilizing different configurations of laser interferometers todetermine the yaw of the substrate 16 at each writing cycle.

In this regard, FIG. 5 depicts a yaw detection apparatus 44(2)comprising laser interferometers 50A-50H measuring a position and yaw ofthe stage 40 at the beginning of a writing cycle, wherein a previousposition 52 of the stage 40 and a previous position 53 of the substrate16 in the previous writing cycle are shown in broken lines. The stage 40may be supporting the substrate 16 and the stage 40 and the substrate 16are considered to be stationary relative to each other. The laserinterferometers 50A-50H may be mounted in stationary locations and mayreflect laser beams 54A-54H, respectively against the stage 40 tomeasure a position of the stage 40, including yaw. The interferometers50A-50B may reflect at a side 55A of the stage 40, the interferometers50C-50D may reflect at a side 55B of the stage 40, the interferometers50E-50F may reflect at a side 55C of the stage 40, and theinterferometers 50G-50H may reflect at a side 55D of the stage 40.Variances of calculations of the position and/or the yaw of the stage 40using different combinations of the interferometers 50A-50H may beresolved by the computer processor 32, for example, by averaging. Inthis way, the position and yaw of the stage 40 and the substrate 16supported thereon may be determined at each of the writing cycles, so adesired location of that the pattern 15 may be determined with respectto the substrate 16.

Another embodiment of the yaw detection apparatus is possible. FIG. 6depicts a yaw detection apparatus 44(3) comprising laser interferometers56A-56D directly measuring a position and yaw of the substrate 16 at thebeginning of a writing cycle, wherein a previous position 58 of thestage 40 and a previous position 60 of the substrate 16 in the previouswriting cycle are shown in broken lines. The stage 40 may support thesubstrate 16 and may move relative to each other. The laserinterferometers 56A-56D may be mounted in stationary locations and mayreflect laser beams 62A-62D, respectively against the substrate 16 todirectly measure a position of the substrate 16, including yaw. In thisregard, the interferometers 56A-56B may reflect against adjacent sides64A, 64B of the substrate 16 at a corner 66A of the substrate 16 andinterferometers 56C-56D may reflect at adjacent sides 64C, 64D of thesubstrate 16 at a corner 66B of the substrate 16. The corners 66A, 66Bof the substrate 16 may be opposite each other across a diagonal of thesubstrate 16 having a rectangular shape. Variances of calculations ofthe position and/or the yaw of the substrate 16 using differentcombinations of the interferometers 56A-56D may be resolved by thecomputer processor 32, for example, by averaging. In this manner, theposition and the yaw of the substrate 16 may be determined directly foreach of the writing cycles without error due to relative movementbetween the substrate 16 and the stage 40.

Many modifications and other embodiments not set forth herein will cometo mind to one skilled in the art to which the embodiments pertainhaving the benefit of the teachings presented in the foregoingdescriptions and the associated drawings. Therefore, it is to beunderstood that the description and claims are not to be limited to thespecific embodiments disclosed and that modifications and otherembodiments are intended to be included within the scope of the appendedclaims. It is intended that the embodiments cover the modifications andvariations of the embodiments provided they come within the scope of theappended claims and their equivalents. Although specific terms areemployed herein, they are used in a generic and descriptive sense onlyand not for purposes of limitation.

While the foregoing is directed to embodiments of the present invention,other and further embodiments of the invention may be devised withoutdeparting from the basic scope thereof, and the scope thereof isdetermined by the claims that follow.

What is claimed is:
 1. A pattern generator, comprising: a stageconfigured to support a substrate and move the substrate to differentwriting cycle zone positions with respect to a spatial light modulator(SLM) for each of a plurality of writing cycles; a light sourceconfigured to emit light; the SLM, wherein each mirror of the SLM isconfigured to be individually digitally controlled from an inactiveposition to an active position during the writing cycles to reflect arespective portion of the light to the substrate; a computer processorconfigured to receive pattern data comprising an arrangement of polygonsof a pattern, identify whether the mirrors of the SLM are to be actuatedto active positions during each of the writing cycles, determine yaw ofthe substrate, and compensate for yaw of the substrate in each of thewriting cycles by digitally controlling respective mirrors of the SLM toactive or inactive positions, and laser interferometers for determiningcorner positions of the substrate for every one of the writing cycles,wherein the computer processor is configured to determine yaw from thecorner positions of the substrate.
 2. The pattern generator of claim 1,wherein the computer processor is configured to identify whether mirrorsof the SLM are to be actuated for a writing cycle after an immediatelyprevious writing cycle has begun.
 3. The pattern generator of claim 1,wherein the computer processor is configured to determine yaw forrespective ones of the writing cycles based on a plurality of metrologymeasurements determined at a frequency higher than a speed of thewriting cycle.
 4. The pattern generator of claim 1, wherein the writingcycle zone positions for different ones of the writing cycles at leastpartially overlap.
 5. The pattern generator of claim 1, wherein thecomputer processor is configured to actuate a respective mirror of theSLM to the active position during a writing cycle when the respectiveportion of the light of the respective mirror would be incident on thesubstrate within one or more desired polygons of the pattern asdetermined by the computer processor.
 6. The pattern generator of claim1, wherein the substrate comprises a rectangular-shaped surface forreceiving the pattern, and the rectangular-shaped surface includes alength of at least 2.4 meters and a width of at least 2.1 meters.
 7. Thepattern generator of claim 1, wherein the pattern data is in graphicdatabase system (GDS) format.
 8. A pattern generator, comprising: astage configured to support a substrate and move the substrate todifferent writing cycle zone positions with respect to a spatial lightmodulator (SLM) for each of a plurality of writing cycles; a lightsource configured to emit light; the SLM, wherein each mirror of the SLMis configured to be individually digitally controlled from an inactiveposition to an active position during the writing cycles to reflect arespective portion of the light to the substrate; and a computerprocessor configured to receive pattern data comprising an arrangementof polygons of a pattern, identify whether the mirrors of the SLM are tobe actuated to active positions during each of the writing cycles,determine yaw of the substrate, categorize determined values of the yawinto a high frequency portion of the yaw and a low frequency portion ofthe yaw, wherein the high frequency yaw occurs with a frequency above athreshold frequency, and compensate for yaw of the substrate in each ofthe writing cycles by digitally controlling respective mirrors of theSLM to active or inactive positions.
 9. The pattern generator of claim8, wherein the computer processor is configured to compensate for thelow frequency portion of the yaw by instructing at least one motor ofthe stage to modify a movement of the stage, and the computer processoris configured to compensate for the high frequency portion of the yaw bydigitally controlling respective mirrors of the SLM.
 10. The patterngenerator of claim 8, wherein the threshold frequency is in a range froma half (0.5) hertz to two-hundred (200) hertz.
 11. The pattern generatorof claim 10, wherein the writing cycles occur at speeds of at least five(5) kilohertz.
 12. The pattern generator of claim 8, further comprisinglaser interferometers for determining corner positions of the stage forevery one of the writing cycles, wherein the computer processor isconfigured to determine yaw from the corner positions of the stage. 13.A method of writing a pattern on a substrate with a multibeam patterngenerator, comprising: writing portions of the pattern within a writingcycle zone location on the substrate during writing cycles with opticalbeams of light by determining and digitally controlling respective onesof mirrors of a spatial light modulator (SLM) to either an activeposition or an inactive position; moving the substrate with respect tothe SLM to another writing cycle zone location for each of the writingcycles; and determining yaw of the substrate for each of the writingcycles, wherein determining the yaw comprises directly measuring cornerpositions of the substrate with at least one laser interferometerincident on each of four sides of the substrate, and the digitallycontrolling respective ones of mirrors includes compensating for thedetermined yaw by controlling the mirrors to either the active orinactive positions.
 14. The method of claim 13, wherein the digitallycontrolling comprises actuating the respective ones of the mirrors ofthe SLM to the active position during a writing cycle when opticalpathways associated with the respective ones of the mirrors would beincident upon one or more desired polygons of the pattern on thesubstrate.
 15. The method of claim 14, wherein the location of the oneor more desired polygons on the substrate are determined based on theyaw.
 16. A method of writing a pattern on a substrate with a multibeampattern generator, comprising: writing portions of the pattern within awriting cycle zone location on the substrate during writing cycles withoptical beams of light by determining and digitally controllingrespective ones of mirrors of a spatial light modulator (SLM) to eitheran active position or an inactive position; moving the substrate withrespect to the SLM to another writing cycle zone location for each ofthe writing cycles; and determining yaw of the substrate for each of thewriting cycles, wherein the digitally controlling respective ones ofmirrors includes compensating for the determined yaw by controlling themirrors to either the active or inactive positions, and the compensatingfor the determined yaw includes categorizing the determined yaw into ahigh frequency portion of the determined yaw and a low frequency portionof the determined yaw, wherein the high frequency determined yaw occurswith a frequency above a threshold frequency.
 17. The method of claim16, wherein determining the yaw comprises directly measuring with laserinterferometers positions of a stage to determine the yaw of thesubstrate supported by the stage.
 18. The method of claim 16, whereinthe low frequency portion of the yaw is compensated for by instructingat least one motor of a stage to modify a movement of the stage, and thehigh frequency portion of the yaw is compensated for by digitallycontrolling respective mirrors of the SLM.